your cdi went out today.
Its very possible the cdi box isnt reading the idle rpm, and therefore not sending the signal to power the relay, the relays are powered by the cdi box and thats why there is a slight delay when you start these sleds up before the lights come on, its to supply all the available voltage to the ign system be fore the load from the lights is applied to the engine/stator.
8 out of 10 times its most always the wire harness, the problems that can arise from a shorting harness are in the 100's, and all are always a little differnt but, they usually will be related to the tach,dimmer switch for headlight or engine mis fiiring occasionally. In your case, going over eveything in steps only leave the cdi for the realy not powering up. I dont think there is any other explanation when you can jump the relay and everything powers up fine and doesnt drag the engine down from a short somewhere.
Its very possible the cdi box isnt reading the idle rpm, and therefore not sending the signal to power the relay, the relays are powered by the cdi box and thats why there is a slight delay when you start these sleds up before the lights come on, its to supply all the available voltage to the ign system be fore the load from the lights is applied to the engine/stator.
8 out of 10 times its most always the wire harness, the problems that can arise from a shorting harness are in the 100's, and all are always a little differnt but, they usually will be related to the tach,dimmer switch for headlight or engine mis fiiring occasionally. In your case, going over eveything in steps only leave the cdi for the realy not powering up. I dont think there is any other explanation when you can jump the relay and everything powers up fine and doesnt drag the engine down from a short somewhere.
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camviperride
New member
Thanks a ton mr viper.I would't have been able to get to the bottom of this problem without your guidance. i really appreciate it! 
Just a thought ?? Is the relay geting a good ground ??
wilsviper
New member
If you're still having problems,check your wire near the stator.They are too light.
I've had mine burnout.There have been others with same problem.
I've had mine burnout.There have been others with same problem.
littlebear
New member
Hey Camviper. I just had a similiar problem and changed the stator to no avail. I finally found the problem. Two wires were almost broken through right where they bend and go into the voltage regulator/rectifier. The outer casing wasn't broken, but when the sled was idling I could make the headlight flash or the tach to jump or completely kill the engine just by moving those wires around. I made a new plug and connected the wires up about 12 inches and now it's running perfect again. Just my solution, might be worth checking. When it was runniiing it was coughiing and sputterinig and the brake lever or high beam would make the engine die.
clint
clint
Electrical problems can be real fun (very frustrating at times). I just fixed a damaged wire harness this past weekend between rides. It is not real fun when everything goes black at 50 mph in the woods. You get to ride from a brief memory of what was ahead of you until you can get it stopped. Mine was simply a hood harness meltdown from getting too close to the exhaust pipe (too much slack between ties).
Don was right on target with his advice on diagnosing this problem. One of the things that I have learned over the years in diagnosing electrical problems, is to employ the process of elimination (basically what you guys did). Keep testing the circuitry in a manner that cuts it in half, and then in half again, etc. until you find a very small area where the problem exists. (this is known as a binary search in the computer world)
One thing to note . . .
If the Brown wire at the Main Control Relay has good power to ground, and the Brown/White at the Main Control Relay is completing the circuit to ground (back at the CDI), then the relay should be connecting the Red to the Blue which supplies regulated power for the lighting circuit, etc. One way to test this is to take the Brown/White out of the wire plug and briefly touch ground with it while engine is running. The lights should come on. This would help verify that the CDI is not completing the circuit.
Don was right on target with his advice on diagnosing this problem. One of the things that I have learned over the years in diagnosing electrical problems, is to employ the process of elimination (basically what you guys did). Keep testing the circuitry in a manner that cuts it in half, and then in half again, etc. until you find a very small area where the problem exists. (this is known as a binary search in the computer world)
One thing to note . . .
If the Brown wire at the Main Control Relay has good power to ground, and the Brown/White at the Main Control Relay is completing the circuit to ground (back at the CDI), then the relay should be connecting the Red to the Blue which supplies regulated power for the lighting circuit, etc. One way to test this is to take the Brown/White out of the wire plug and briefly touch ground with it while engine is running. The lights should come on. This would help verify that the CDI is not completing the circuit.
camviperride
New member
Mr. Viper...Thanks again for all the help. Got the new cdi today and plugged her in. Runs like a million. I just want everyone to know I appreciate all the help and posts you all gave. 
Now ......the viper hisses again!!! 
Now ......the viper hisses again!!!
Great !!!
No need to thank me, I enjoy helping solve these problems, some people do crossword puzzles, I like electrical problems and getting sleds to run when others have given up!
Glad you are back in bussiness, have fun and ride safe!
Glad you are back in bussiness, have fun and ride safe!